Aerosol delivery device including a control body, an atomizer body, and a cartridge and related methods

ABSTRACT

The present disclosure relates to aerosol delivery devices. The aerosol delivery devices may include a control body, an atomizer body including an atomizer, and a cartridge including a reservoir configured to contain an aerosol precursor composition. The control body may be configured to releasably engage the atomizer body and the atomizer body may be configured to releasably engage the cartridge. The atomizer may be configured to receive an electrical current from the control body and the aerosol precursor composition from the cartridge to produce an aerosol.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/782,543, filed on Oct. 12, 2017, which is incorporated herein in itsentirety by reference.

BACKGROUND Field of the Disclosure

The present disclosure relates to aerosol delivery devices such aselectronic cigarettes, and more particularly to aerosol delivery devicesincluding an atomizer. The atomizer may be configured to heat an aerosolprecursor composition, which may be made or derived from tobacco orotherwise incorporate tobacco, to form an inhalable substance for humanconsumption.

Description of Related Art

Many devices have been proposed through the years as improvements upon,or alternatives to, smoking products that require combusting tobacco foruse. Many of those devices purportedly have been designed to provide thesensations associated with cigarette, cigar, or pipe smoking, butwithout delivering considerable quantities of incomplete combustion andpyrolysis products that result from the burning of tobacco. To this end,there have been proposed numerous alternative smoking products, flavorgenerators, and medicinal inhalers that utilize electrical energy tovaporize or heat a volatile material, or attempt to provide thesensations of cigarette, cigar, or pipe smoking without burning tobaccoto a significant degree. See, for example, the various alternativesmoking articles, aerosol delivery devices and heat generating sourcesset forth in the background art described in U.S. Pat. No. 8,881,737 toCollett et al., U.S. Pat. App. Pub. No. 2013/0255702 to Griffith Jr. etal., U.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., U.S. Pat.App. Pub. No. 2014/0096781 to Sears et al., U.S. Pat. App. Pub. No.2014/0096782 to Ampolini et al., and U.S. Pat. App. Pub. No.2015/0059780 to Davis et al., which are incorporated herein by referencein their entireties. See also, for example, the various embodiments ofproducts and heating configurations described in the background sectionsof U.S. Pat. No. 5,388,594 to Counts et al. and U.S. Pat. No. 8,079,371to Robinson et al., which are incorporated by reference in theirentireties.

However, it may be desirable to provide aerosol delivery devices withalternate configurations. Thus, advances with respect to aerosoldelivery devices may be desirable.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices configured toproduce aerosol and which aerosol delivery devices, in some embodiments,may be referred to as electronic cigarettes. In one aspect, an aerosoldelivery device is provided. The aerosol delivery device may include acontrol body, an atomizer body including an atomizer, and a cartridge.The cartridge may include a reservoir configured to contain an aerosolprecursor composition. The cartridge may further include a valveassembly configured to dispense the aerosol precursor composition to theatomizer body when the cartridge is engaged with the atomizer body. Thevalve assembly may include a dispensing seal and a reservoir seal. Thecontrol body may be configured to releasably engage the atomizer bodyand the atomizer body may be configured to releasably engage thecartridge. The atomizer may be configured to receive an electricalcurrent from the control body and the aerosol precursor composition fromthe cartridge to produce an aerosol.

In some embodiments the cartridge may include one or more air flowapertures extending from the atomizer body to a mouthpiece. The air flowapertures may be configured to direct the aerosol therethrough. At leastone of the air flow apertures may extend through the valve assembly. Thevalve assembly may define a dispensing capillary tube and may furtherinclude a first plate and a second plate positioned adjacent to oneanother with a space defined therebetween. The dispensing capillary tubemay extend through the first plate to the space between the first plateand the second plate. A gap may be defined between a radial outer edgeof the first plate and a radial outer edge of the second plate and aninner surface of the reservoir.

In some embodiments the atomizer body may further include a nozzleconfigured to extend through the reservoir seal and engage thedispensing seal. The valve assembly may further include a frame and thereservoir seal may be molded to the frame. The atomizer may include aliquid transport element that may include a porous monolith. Theatomizer may further include a heating element that may include a wireat least partially imbedded in the liquid transport element. The liquidtransport element may define a tube and the atomizer may further includea capillary rod extending through the liquid transport element andconfigured to direct the aerosol precursor composition therethrough. Thecontrol body may further include a microphone. The microphone may beconfigured to detect a user draw on the cartridge.

In some embodiments, the atomizer may comprise an outer body, a terminalbase, a flow director, and a liquid transport element comprising aporous monolith, and an atomizer chamber may be created by the flowdirector, the terminal base, and an inside surface of the liquidtransport element. The flow director may include a central inlet airchannel, a transition barrier, and one or more radial inlet air holesconfigured such that air that enters through the inlet air channel maybe directed through the one or more radial inlet air holes by thetransition barrier. The flow director may further include one or moreinlet liquid flow chambers configured to deliver the aerosol precursorcomposition to the liquid transport element. The outer body may includeone or more vapor apertures, and the flow director may further includeone or more radial inlet vapor holes, one or more radial vapor channels,and one or more vertical vapor holes, configured such that the aerosolmay be directed through the one or more radial inlet vapor holes, theone or more radial vapor channels, the one or more vertical vapor holesof the flow director, and the one or more vapor apertures of the outerbody and into one or more vapor channels of the cartridge.

In an additional aspect, an aerosol delivery device operation method isprovided. The aerosol delivery device operation method may includedirecting an aerosol precursor composition from a reservoir of acartridge out of the cartridge through a valve assembly by directing theaerosol precursor composition through a dispensing seal and a reservoirseal at the reservoir. The method may further include receiving theaerosol precursor composition in an atomizer body. Additionally, themethod may include directing the aerosol precursor composition to anatomizer in the atomizer body. Further, the method may include directingan electrical current from a control body to the atomizer to produce anaerosol.

In some embodiments the valve assembly may define a dispensing capillarytube and directing the aerosol precursor composition out of thecartridge through the valve assembly may further include directing theaerosol precursor composition between a first plate and a second platepositioned adjacent to one another with a space defined therebetween andout of the space through the dispensing capillary tube extending throughthe first plate. Directing the aerosol precursor composition out of thecartridge through the valve assembly may further include engaging anozzle of the atomizer body with the valve assembly. Engaging the nozzlewith the valve assembly may include directing the nozzle through thereservoir seal of the valve assembly. Engaging the nozzle with the valveassembly may further include engaging the nozzle with the dispensingseal of the valve assembly at the dispensing capillary tube.

In some embodiments receiving the aerosol precursor composition in theatomizer body may include directing the aerosol precursor compositionbetween the nozzle and a capillary rod. Directing the aerosol precursorcomposition to the atomizer in the atomizer body may include directingthe aerosol precursor composition between the capillary rod and a liquidtransport element of the atomizer. The method may further includedirecting the aerosol through one or more air flow apertures extendingthrough the cartridge. Directing the aerosol through one or more airflow apertures extending through the cartridge may include directing theaerosol through the valve assembly.

In some embodiments, directing the aerosol precursor composition to anatomizer in the atomizer body may comprise directing the aerosolprecursor composition through one or more radial flow openings in anouter body of the atomizer and through one or more inlet liquid flowchannel in a flow director of the atomizer. Some embodiments may furthercomprise directing the aerosol through one or more radial inlet vaporholes, one or more radial vapor channels, and one or more vertical vaporholes of the flow director, one or more vapor apertures of an outer bodyof the atomizer, and into one or more vapor channels of the cartridge.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a side view of an aerosol delivery device comprisinga cartridge and a control body in an assembled configuration accordingto an example embodiment of the present disclosure;

FIG. 2 illustrates the control body of FIG. 1 in an explodedconfiguration according to an example embodiment of the presentdisclosure;

FIG. 3 illustrates the cartridge of FIG. 1 in an exploded configurationaccording to an example embodiment of the present disclosure;

FIG. 4 illustrates a perspective view of an aerosol delivery deviceincluding a cartridge, an atomizer body, and a control body in adecoupled configuration according to an example embodiment of thepresent disclosure;

FIG. 5 illustrates an exploded view of the cartridge of FIG. 4 includinga reservoir and a valve assembly according to an example embodiment ofthe present disclosure;

FIG. 6 illustrates a perspective view of filling of the reservoir ofFIG. 5 according to an example embodiment of the present disclosure;

FIG. 7 illustrates a perspective view of the valve assembly of FIG. 5according to an example embodiment of the present disclosure;

FIG. 8 illustrates an exploded view of the atomizer body of FIG. 4including an outer body, an atomizer, and a coupler according to anexample embodiment of the present disclosure;

FIG. 9 illustrates an exploded view of the atomizer of FIG. 8 accordingto an example embodiment of the present disclosure;

FIG. 10 illustrates an exploded view of the coupler and terminals of theatomizer body of FIG. 4 according to an example embodiment of thepresent disclosure;

FIG. 11 illustrates a perspective view of the coupler and the terminalsof FIG. 10 in an assembled configuration according to an exampleembodiment of the present disclosure;

FIG. 12 illustrates a partially assembled, partially exploded view ofpart of the atomizer body of FIG. 4 according to an example embodimentof the present disclosure;

FIG. 13 illustrates a modified sectional view through the aerosoldelivery device of FIG. 4 according to an example embodiment of thepresent disclosure;

FIG. 14 illustrates a modified sectional view through the aerosoldelivery device of FIG. 4 at the cartridge according to an exampleembodiment of the present disclosure;

FIG. 15 illustrates an enlarged view of area Z from FIG. 14 according toan example embodiment of the present disclosure;

FIG. 16 illustrates a perspective end view of the cartridge of FIG. 4according to an example embodiment of the present disclosure;

FIG. 17 schematically illustrates an aerosol delivery device operationmethod according to an example embodiment of the present disclosure;

FIG. 18 illustrates a cartridge and an atomizer according to anadditional example embodiment of the present disclosure;

FIG. 19 illustrates the atomizer of FIG. 18 in an assembledconfiguration according to an example embodiment of the presentdisclosure;

FIG. 20 illustrates the atomizer of FIG. 18 an exploded configurationaccording to an example embodiment of the present disclosure;

FIG. 21 illustrates a cartridge for use with the atomizer of FIG. 18according to an example embodiment of the present disclosure;

FIG. 22 illustrates a bottom view of the cartridge of FIG. 21 accordingto an example embodiment of the present disclosure;

FIG. 23 illustrates a liquid transport element and a heating element foruse with the atomizer of FIG. 18 according to an example embodiment ofthe present disclosure;

FIG. 24 illustrates a flow director for use with the atomizer of FIG. 18according to an example embodiment of the present disclosure;

FIG. 25 illustrates a cross-section of the flow director of FIG. 24according to an example embodiment of the present disclosure;

FIG. 26 illustrates a partial cross-section of the atomizer of FIG. 18according to an example embodiment of the present disclosure;

FIG. 27 illustrates a different partial cross-section of the atomizer ofFIG. 18 according to an example embodiment of the present disclosure;and

FIG. 28 illustrates a partial front view of the cartridge of FIG. 23according to an example embodiment of the present disclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural variations unless the context clearly dictates otherwise.

The present disclosure provides descriptions of aerosol deliverydevices. The aerosol delivery devices may use electrical energy to heata material (preferably without combusting the material to anysignificant degree) to form an inhalable substance; such articles mostpreferably being sufficiently compact to be considered “hand-held”devices. An aerosol delivery device may provide some or all of thesensations (e.g., inhalation and exhalation rituals, types of tastes orflavors, organoleptic effects, physical feel, use rituals, visual cuessuch as those provided by visible aerosol, and the like) of smoking acigarette, cigar, or pipe, without any substantial degree of combustionof any component of that article or device. The aerosol delivery devicemay not produce smoke in the sense of the aerosol resulting fromby-products of combustion or pyrolysis of tobacco, but rather, that thearticle or device most preferably yields vapors (including vapors withinaerosols that can be considered to be visible aerosols that might beconsidered to be described as smoke-like) resulting from volatilizationor vaporization of certain components of the article or device, althoughin other embodiments the aerosol may not be visible. In highly preferredembodiments, aerosol delivery devices may incorporate tobacco and/orcomponents derived from tobacco. As such, the aerosol delivery devicecan be characterized as an electronic smoking article such as anelectronic cigarette or “e-cigarette.”

While the systems are generally described herein in terms of embodimentsassociated with aerosol delivery devices such as so-called“e-cigarettes,” it should be understood that the mechanisms, components,features, and methods may be embodied in many different forms andassociated with a variety of articles. For example, the descriptionprovided herein may be employed in conjunction with embodiments oftraditional smoking articles (e.g., cigarettes, cigars, pipes, etc.),heat-not-burn cigarettes, and related packaging for any of the productsdisclosed herein. Accordingly, it should be understood that thedescription of the mechanisms, components, features, and methodsdisclosed herein are discussed in terms of embodiments relating toaerosol delivery devices by way of example only, and may be embodied andused in various other products and methods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer shell or body. The overalldesign of the outer shell or body can vary, and the format orconfiguration of the outer body that can define the overall size andshape of the aerosol delivery device can vary. Typically, an elongatedbody resembling the shape of a cigarette or cigar can be a formed from asingle, unitary shell; or the elongated body can be formed of two ormore separable pieces. For example, an aerosol delivery device cancomprise an elongated shell or body that can be substantially tubular inshape and, as such, resemble the shape of a conventional cigarette orcigar. However, various other shapes and configurations may be employedin other embodiments (e.g., rectangular or fob-shaped).

In one embodiment, all of the components of the aerosol delivery deviceare contained within one outer body or shell. Alternatively, an aerosoldelivery device can comprise two or more shells that are joined and areseparable. For example, an aerosol delivery device can possess at oneend a control body comprising a shell containing one or more reusablecomponents (e.g., a rechargeable battery and various electronics forcontrolling the operation of that article), and at the other end andremovably attached thereto a shell containing a disposable portion(e.g., a disposable flavor-containing cartridge). More specific formats,configurations and arrangements of components within the single shelltype of unit or within a multi-piece separable shell type of unit willbe evident in light of the further disclosure provided herein.Additionally, various aerosol delivery device designs and componentarrangements can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and/or ceasing power for heat generation, suchas by controlling electrical current flow from the power source to othercomponents of the aerosol delivery device), a heater or heat generationcomponent (e.g., an electrical resistance heating element or componentcommonly referred to as part of an “atomizer”), and an aerosol precursorcomposition (e.g., commonly a liquid capable of yielding an aerosol uponapplication of sufficient heat, such as ingredients commonly referred toas “smoke juice,” “e-liquid” and “e-juice”), and a mouthend region ortip for allowing draw upon the aerosol delivery device for aerosolinhalation (e.g., a defined air flow path through the article such thataerosol generated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific embodiments, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement can be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, an aerosol is formed, released, orgenerated in a physical form suitable for inhalation by a consumer. Itshould be noted that the foregoing terms are meant to be interchangeablesuch that reference to release, releasing, releases, or releasedincludes form or generate, forming or generating, forms or generates,and formed or generated. Specifically, an inhalable substance isreleased in the form of a vapor or aerosol or mixture thereof, whereinsuch terms are also interchangeably used herein except where otherwisespecified.

As noted above, the aerosol delivery device may incorporate a batteryand/or other electrical power source (e.g., a capacitor) to providecurrent flow sufficient to provide various functionalities to theaerosol delivery device, such as powering of a heater, powering ofcontrol systems, powering of indicators, and the like. The power sourcecan take on various embodiments. Preferably, the power source is able todeliver sufficient power to rapidly heat the heating element to providefor aerosol formation and power the aerosol delivery device through usefor a desired duration of time. The power source preferably is sized tofit conveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled. Additionally, a preferred powersource is of a sufficiently light weight to not detract from a desirablesmoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices. Further, the arrangementof the components within the aerosol delivery device can also beappreciated upon consideration of the commercially available electronicaerosol delivery devices. Examples of commercially available products,for which the components thereof, methods of operation thereof,materials included therein, and/or other attributes thereof may beincluded in the devices of the present disclosure as well asmanufacturers, designers, and/or assignees of components and relatedtechnologies that may be employed in the aerosol delivery device of thepresent disclosure are described in U.S. patent application Ser. No.15/222,615, filed Jul. 28, 2016, to Watson et al., which is incorporatedherein by reference in its entirety.

One example embodiment of an aerosol delivery device 100 is illustratedin FIG. 1. In particular, FIG. 1 illustrates an aerosol delivery device100 including a control body 200 and a cartridge 300. The control body200 and the cartridge 300 can be permanently or detachably aligned in afunctioning relationship. Various mechanisms may connect the cartridge300 to the control body 200 to result in a threaded engagement, apress-fit engagement, an interference fit, a magnetic engagement, or thelike. The aerosol delivery device 100 may be substantially rod-like,substantially tubular shaped, or substantially cylindrically shaped insome embodiments when the cartridge 300 and the control body 200 are inan assembled configuration. However, as noted above, various otherconfigurations such as rectangular or fob-shaped may be employed inother embodiments. Further, although the aerosol delivery devices aregenerally described herein as resembling the size and shape of atraditional smoking article, in other embodiments differingconfigurations and larger capacity reservoirs, which may be referred toas “tanks,” may be employed.

In specific embodiments, one or both of the cartridge 300 and thecontrol body 200 may be referred to as being disposable or as beingreusable. For example, the control body 200 may have a replaceablebattery or a rechargeable battery and/or capacitor and thus may becombined with any type of recharging technology, including connection toa typical alternating current electrical outlet, connection to a carcharger (i.e., cigarette lighter receptacle), and connection to acomputer, such as through a universal serial bus (USB) cable. Further,in some embodiments the cartridge 300 may comprise a single-usecartridge, as disclosed in U.S. Pat. No. 8,910,639 to Chang et al.,which is incorporated herein by reference in its entirety.

FIG. 2 illustrates an exploded view of the control body 200 of theaerosol delivery device 100 (see, FIG. 1) according to an exampleembodiment of the present disclosure. As illustrated, the control body200 may comprise a coupler 202, an outer body 204, a sealing member 206,an adhesive member 208 (e.g., KAPTON® tape), a flow sensor 210 (e.g., apuff sensor or pressure switch), a control component 212, a spacer 214,an electrical power source 216 (e.g., a capacitor and/or a battery,which may be rechargeable), a circuit board with an indicator 218 (e.g.,a light emitting diode (LED)), a connector circuit 220, and an end cap222. Examples of electrical power sources are described in U.S. Pat. No.9,484,155 to Peckerar et al., the disclosure of which is incorporatedherein by reference in its entirety.

With respect to the flow sensor 210, representative current regulatingcomponents and other current controlling components including variousmicrocontrollers, sensors, and switches for aerosol delivery devices aredescribed in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No.8,205,622 to Pan, all of which are incorporated herein by reference intheir entireties. Reference also is made to the control schemesdescribed in U.S. Pat. No. 9,423,152 to Ampolini et al., which isincorporated herein by reference in its entirety.

In one embodiment the indicator 218 may comprise one or more lightemitting diodes. The indicator 218 can be in communication with thecontrol component 212 through the connector circuit 220 and beilluminated, for example, during a user draw on a cartridge coupled tothe coupler 202, as detected by the flow sensor 210. The end cap 222 maybe adapted to make visible the illumination provided thereunder by theindicator 218. Accordingly, the indicator 218 may be illuminated duringuse of the aerosol delivery device 100 to simulate the lit end of asmoking article. However, in other embodiments the indicator 218 can beprovided in varying numbers and can take on different shapes and caneven be an opening in the outer body (such as for release of sound whensuch indicators are present).

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators for smoking articles; U.S. Pat. No.5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can beassociated with the mouth-end of a device to detect user lip activityassociated with taking a draw and then trigger heating of a heatingdevice; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puffsensor for controlling energy flow into a heating load array in responseto pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harriset al. discloses receptacles in a smoking device that include anidentifier that detects a non-uniformity in infrared transmissivity ofan inserted component and a controller that executes a detection routineas the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and WO 2010/003480 by Flick discloses a fluid flowsensing system indicative of a puff in an aerosol generating system; allof the foregoing disclosures being incorporated herein by reference intheir entireties. Further examples of components related to electronicaerosol delivery articles and disclosing materials or components thatmay be used in the present article include U.S. Pat. No. 4,735,217 toGerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No.5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.;U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S.Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols;U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi;U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No. 6,772,756 to Shayan;U.S. Pat. Nos. 8,156,944 and 8,375,957 to Hon; U.S. Pat. No. 8,794,231to Thorens et al.; U.S. Pat. No. 8,851,083 to Oglesby et al.; U.S. Pat.Nos. 8,915,254 and 8,925,555 to Monsees et al.; and U.S. Pat. No.9,220,302 to DePiano et al.; U.S. Pat. App. Pub. Nos. 2006/0196518 and2009/0188490 to Hon; U.S. Pat. App. Pub. No. 2010/0024834 to Oglesby etal.; U.S. Pat. App. Pub. No. 2010/0307518 to Wang; WO 2010/091593 toHon; and WO 2013/089551 to Foo, each of which is incorporated herein byreference in its entirety. A variety of the materials disclosed by theforegoing documents may be incorporated into the present devices invarious embodiments, and all of the foregoing disclosures areincorporated herein by reference in their entireties.

FIG. 3 illustrates the cartridge 300 of the aerosol delivery device 100(see, FIG. 1) in an exploded configuration. As illustrated, thecartridge 300 may comprise a base 302, a control component terminal 304,an electronic component 306, a flow director 308, an atomizer 310, areservoir 312 (e.g., a reservoir substrate), an outer body 314, amouthpiece 316, a label 318, and first and second heating terminals 320,321 according to an example embodiment of the present disclosure.

In some embodiments the first and second heating terminals 320, 321 maybe embedded in, or otherwise coupled to, the flow director 308. Forexample, the first and second heating terminals 320, 321 may be insertmolded in the flow director 308. Accordingly, the flow director 308 andthe first and second heating terminals are collectively referred toherein as a flow director assembly 322. Additional description withrespect to the first and second heating terminals 320, 321 and the flowdirector 308 is provided in U.S. Pat. Pub. No. 2015/0335071 to Brinkleyet al., which is incorporated herein by reference in its entirety.

The atomizer 310 may comprise a liquid transport element 324 and aheating element 326. The cartridge may additionally include a baseshipping plug engaged with the base and/or a mouthpiece shipping plugengaged with the mouthpiece in order to protect the base and themouthpiece and prevent entry of contaminants therein prior to use asdisclosed, for example, in U.S. Pat. No. 9,220,302 to Depiano et al.,which is incorporated herein by reference in its entirety.

The base 302 may be coupled to a first end of the outer body 314 and themouthpiece 316 may be coupled to an opposing second end of the outerbody to substantially or fully enclose other components of the cartridge300 therein. For example, the control component terminal 304, theelectronic component 306, the flow director 308, the atomizer 310, andthe reservoir 312 may be substantially or entirely retained within theouter body 314. The label 318 may at least partially surround the outerbody 314, and optionally the base 302, and include information such as aproduct identifier thereon. The base 302 may be configured to engage thecoupler 202 of the control body 200 (see, e.g., FIG. 2). In someembodiments the base 302 may comprise anti-rotation features thatsubstantially prevent relative rotation between the cartridge and thecontrol body as disclosed in U.S. Pat. App. Pub. No. 2014/0261495 toNovak et al., which is incorporated herein by reference in its entirety.

The reservoir 312 may be configured to hold an aerosol precursorcomposition. Representative types of aerosol precursor components andformulations are also set forth and characterized in U.S. Pat. No.7,726,320 to Robinson et al., U.S. Pat. No. 8,881,737 to Collett et al.,and U.S. Pat. No. 9,254,002 to Chong et al.; and U.S. Pat. Pub. Nos.2013/0008457 to Zheng et al.; 2015/0020823 to Lipowicz et al.; and2015/0020830 to Koller, as well as WO 2014/182736 to Bowen et al, thedisclosures of which are incorporated herein by reference. Other aerosolprecursors that may be employed include the aerosol precursors that havebeen incorporated in the VUSE® product by R. J. Reynolds Vapor Company,the BLU product by Lorillard Technologies, the MISTIC MENTHOL product byMistic Ecigs, and the VYPE product by CN Creative Ltd. Also desirableare the so-called “smoke juices” for electronic cigarettes that havebeen available from Johnson Creek Enterprises LLC. Embodiments ofeffervescent materials can be used with the aerosol precursor, and aredescribed, by way of example, in U.S. Pat. App. Pub. No. 2012/0055494 toHunt et al., which is incorporated herein by reference. Further, the useof effervescent materials is described, for example, in U.S. Pat. No.4,639,368 to Niazi et al.; U.S. Pat. No. 5,178,878 to Wehling et al.;U.S. Pat. No. 5,223,264 to Wehling et al.; U.S. Pat. No. 6,974,590 toPather et al.; U.S. Pat. No. 7,381,667 to Bergquist et al.; U.S. Pat.No. 8,424,541 to Crawford et al; U.S. Pat. No. 8,627,828 to Stricklandet al.; and U.S. Pat. No. 9,307,787 to Sun et al.; as well as U.S. Pat.App. Pub. No. 2010/0018539 to Brinkley et al. and PCT WO 97/06786 toJohnson et al., all of which are incorporated by reference herein.Additional description with respect to embodiments of aerosol precursorcompositions, including description of tobacco or components derivedfrom tobacco included therein, is provided in U.S. patent applicationSer. Nos. 15/216,582 and 15/216,590, each filed Jul. 21, 2016 and eachto Davis et al., which are incorporated herein by reference in theirentireties.

The reservoir 312 may comprise a plurality of layers of nonwoven fibersformed into the shape of a tube encircling the interior of the outerbody 314 of the cartridge 300. Thus, liquid components, for example, canbe sorptively retained by the reservoir 312. The reservoir 312 is influid connection with the liquid transport element 324. Thus, the liquidtransport element 324 may be configured to transport liquid from thereservoir 312 to the heating element 326 via capillary action or otherliquid transport mechanism.

As illustrated, the liquid transport element 324 may be in directcontact with the heating element 326. As further illustrated in FIG. 3,the heating element 326 may comprise a wire defining a plurality ofcoils wound about the liquid transport element 324. In some embodimentsthe heating element 326 may be formed by winding the wire about theliquid transport element 324 as described in U.S. Pat. No. 9,210,738 toWard et al., which is incorporated herein by reference in its entirety.Further, in some embodiments the wire may define a variable coilspacing, as described in U.S. Pat. No. 9,277,770 to DePiano et al.,which is incorporated herein by reference in its entirety. Variousembodiments of materials configured to produce heat when electricalcurrent is applied therethrough may be employed to form the heatingelement 326. Example materials from which the wire coil may be formedinclude Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂),molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum(Mo(Si,Al)₂), graphite and graphite-based materials; and ceramic (e.g.,a positive or negative temperature coefficient ceramic).

However, various other embodiments of methods may be employed to formthe heating element 326, and various other embodiments of heatingelements may be employed in the atomizer 310. For example, a stampedheating element may be employed in the atomizer, as described in U.S.Pat. App. Pub. No. 2014/0270729 to DePiano et al., which is incorporatedherein by reference in its entirety. Further to the above, additionalrepresentative heating elements and materials for use therein aredescribed in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. No.5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi et al.; U.S.Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No. 5,322,075 toDeevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No.5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No.5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No.5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat.No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhaueret al., the disclosures of which are incorporated herein by reference intheir entireties. Further, chemical heating may be employed in otherembodiments. Various additional examples of heaters and materialsemployed to form heaters are described in U.S. Pat. No. 8,881,737 toCollett et al., which is incorporated herein by reference, as notedabove.

A variety of heater components may be used in the present aerosoldelivery device. In various embodiments, one or more microheaters orlike solid state heaters may be used. Microheaters and atomizersincorporating microheaters suitable for use in the presently discloseddevices are described in U.S. Pat. No. 8,881,737 to Collett et al.,which is incorporated herein by reference in its entirety.

The first heating terminal 320 and the second heating terminal 321(e.g., negative and positive heating terminals) are configured to engageopposing ends of the heating element 326 and to form an electricalconnection with the control body 200 (see, e.g., FIG. 2) when thecartridge 300 is connected thereto. Further, when the control body 200is coupled to the cartridge 300, the electronic component 306 may forman electrical connection with the control body through the controlcomponent terminal 304. The control body 200 may thus employ theelectronic control component 212 (see, FIG. 2) to determine whether thecartridge 300 is genuine and/or perform other functions. Further,various examples of electronic control components and functionsperformed thereby are described in U.S. Pat. App. Pub. No. 2014/0096781to Sears et al., which is incorporated herein by reference in itsentirety.

During use, a user may draw on the mouthpiece 316 of the cartridge 300of the aerosol delivery device 100 (see, FIG. 1). This may pull airthrough an opening in the control body 200 (see, e.g., FIG. 2) or in thecartridge 300. For example, in one embodiment an opening may be definedbetween the coupler 202 and the outer body 204 of the control body 200(see, e.g., FIG. 2), as described in U.S. Pat. No. 9,220,302 to DePianoet al., which is incorporated herein by reference in its entirety.However, the flow of air may be received through other parts of theaerosol delivery device 100 in other embodiments. As noted above, insome embodiments the cartridge 300 may include the flow director 308.The flow director 308 may be configured to direct the flow of airreceived from the control body 200 to the heating element 326 of theatomizer 310.

A sensor in the aerosol delivery device 100 (e.g., the flow sensor 210in the control body 200; see, FIG. 2) may sense the puff. When the puffis sensed, the control body 200 may direct current to the heatingelement 326 through a circuit including the first heating terminal 320and the second heating terminal 321. Accordingly, the heating element326 may vaporize the aerosol precursor composition directed to anaerosolization zone from the reservoir 312 by the liquid transportelement 324. Thus, the mouthpiece 326 may allow passage of air andentrained vapor (i.e., the components of the aerosol precursorcomposition in an inhalable form) from the cartridge 300 to a consumerdrawing thereon.

Various other details with respect to the components that may beincluded in the cartridge 300 are provided, for example, in U.S. Pat.App. Pub. No. 2014/0261495 to DePiano et al., which is incorporatedherein by reference in its entirety. Additional components that may beincluded in the cartridge 300 and details relating thereto are provided,for example, in U.S. Pat. Pub. No. 2015/0335071 to Brinkley et al.,filed May 23, 2014, which is incorporated herein by reference in itsentirety.

Various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Reference is made for example to thereservoir and heater system for controllable delivery of multipleaerosolizable materials in an electronic smoking article disclosed inU.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., which isincorporated herein by reference in its entirety.

In another embodiment substantially the entirety of the cartridge may beformed from one or more carbon materials, which may provide advantagesin terms of biodegradability and absence of wires. In this regard, theheating element may comprise carbon foam, the reservoir may comprisecarbonized fabric, and graphite may be employed to form an electricalconnection with the power source and control component. An exampleembodiment of a carbon-based cartridge is provided in U.S. Pat. App.Pub. No. 2013/0255702 to Griffith et al., which is incorporated hereinby reference in its entirety.

However, in some embodiments it may be desirable to provide aerosoldelivery devices with alternative configurations. In this regard, FIG. 4illustrates an aerosol delivery device 400 according to an exampleembodiment of the present disclosure. Where not otherwise describedand/or illustrated, the components of the aerosol delivery device 400may be substantially similar to, or the same as, correspondingcomponents described above.

As illustrated, the aerosol delivery device may include a control body200. The control body 200 may be similar to, or the same as the controlbody 200 described above (see, FIG. 2), and hence description thereofwill not be repeated. However, in some embodiments the flow sensor 210(see, FIG. 2) may comprise a microphone configured to detect a user drawon the cartridge 500. Further, other embodiments of the control body maybe employed in the aerosol delivery device such as fob-shaped controlbodies.

Further, the aerosol delivery device 400 may include a cartridge 500.The cartridge 500 may differ from the embodiment of the cartridge 300described above with respect to FIGS. 1 and 3. In this regard, thecartridge 500 may not include an atomizer. Rather, the aerosol deliverydevice 400 may further comprise an atomizer body 600, which may includean atomizer, as described in detail below. Thus, whereas the aerosoldelivery device 100 described above with respect to FIG. 1 includes twoseparable components (namely, the control body 200 and the cartridge300), the aerosol delivery device 400 of FIG. 4 includes three separablecomponents (namely, the control body 200, the cartridge 500, and theatomizer body 600).

More particularly, the control body 200 may be configured to releasablyengage the atomizer body 600. Further, the atomizer body 600 may beconfigured to releasably engage the cartridge 500. As describedhereinafter, the atomizer of the atomizer body 600 may be configured toreceive an electrical current from the control body 200 and the aerosolprecursor composition from the cartridge 500 to produce an aerosol.

FIG. 5 illustrates an exploded view of the cartridge 500. Asillustrated, the cartridge 500 may include a reservoir 502 and a valveassembly 504. The reservoir 502 may be configured to contain an aerosolprecursor composition 506. In some embodiments the reservoir 502 maycomprise a translucent or transparent material, such that a user mayview the quantity of the aerosol precursor composition 506 remainingtherein. The aerosol precursor composition 506 may be dispensed orotherwise directed into the reservoir 502. For example, as illustratedin FIG. 6, a filling needle 508 may be directed into the reservoir 502and the aerosol precursor composition 506 may be dispensed therefrom.

Thereafter, the valve assembly 504 may be inserted into the reservoir502. The valve assembly 504 may seal the aerosol precursor composition506 in the reservoir 502. Accordingly, the valve assembly 504 may retainthe aerosol precursor composition 506 in the reservoir 502 withoutrequiring usage of a reservoir substrate. However, as describedhereinafter, the valve assembly 504 may allow the aerosol precursorcomposition 506 to flow to the atomizer body 600 when engaged therewith.

In some embodiments the valve assembly 504 may be affixed to thereservoir 504. For example, the valve assembly 504 may be ultrasonicallywelded to the reservoir 502. As may be understood, various othermechanisms and techniques such as usage of an adhesive may be employedto retain the valve assembly 504 in engagement with the reservoir 502.However, usage of ultrasonic welding may be preferable in that it mayprovide a hermetic seal without requiring an additional component orsubstance to form the seal. Thereby, nondestructive removal of the valveassembly 504 from the reservoir 502 may be prevented, such that thereservoir may not be refilled as described below in greater detail.

FIG. 7 illustrates an enlarged view of the valve assembly 504. Asillustrated, the valve assembly 504 may include a frame 510. A base 512of the frame 510 may be ultrasonically welded to an inner surface of thereservoir 502 to form the cartridge 500 (see, e.g., FIG. 5), asdescribed above. Further, the frame 510 may include at least oneconnector portion 514, a first plate 516, a second plate 518, and atleast one spacer 520. The connector portion 514 may extend from the base512 to the first plate 516. The first plate 516 and the second plate 518may be positioned adjacent to one another with a space definedtherebetween. In this regard, the spacer 520 may extend between andseparate the first plate 516 and the second plate 518 such that thefirst plate and the second plate are separated. A dispensing capillarytube 522 may extend through the first plate 516 to the space definedbetween the first plate and the second plate 518.

Further, the valve assembly 504 may include one or more seals. Inparticular, the valve assembly 504 may include a reservoir seal 524. Thereservoir seal 524 may be configured to seal against the inside of thereservoir 502 to seal the aerosol precursor composition 506 in thereservoir (see, e.g., FIG. 5). The reservoir seal 524 may be molded tothe frame 510 (e.g., insert molded).

Further, the valve assembly 504 may include a dispensing seal 526. Thedispensing seal 526 may be positioned at the dispensing capillary tube522. In particular, the dispensing seal 526 may be configured to sealthe dispensing capillary tube 522 closed.

The reservoir seal 524 and/or the dispensing seal 526 may be molded tothe frame 510. For example, the dispensing seal 526 and/or the reservoirseal 524 may be overmolded on the frame 510. By molding one or both ofthe seals 524, 526 to the frame 510, a strong bond may be formedtherebetween that retains the seals in engagement with the frame.

In some embodiments the frame 510 may comprise a plastic material. Anexample commercially-available material that may be included in theframe 510 is TRITAN copolyester, sold by Eastman Chemical Company ofKingsport, Tenn. Further, in some embodiments the reservoir seal 524and/or the dispensing seal 526 may comprise silicone, thermoplasticpolyurethane, or other resilient material.

Regarding additional components of the aerosol delivery device 400 (see,FIG. 4), the atomizer body 600 is illustrated in a partially explodedconfiguration in FIG. 8. As illustrated, the atomizer body 600 mayinclude an outer body 602. The outer body 602 may be configured toengage a base 604. For example, the outer body 602 may comprise a metalmaterial (e.g., stainless steel), which may be crimped to the base 604,which may comprise a plastic material.

When the outer body 602 is engaged with the base 604, various othercomponents of the atomizer body 600 may be substantially enclosedtherein.

For example, the atomizer body 600 may further comprise an atomizer 606.An example embodiment of the atomizer 606 is illustrated in FIG. 9. Asillustrated, the atomizer 606 may comprise a liquid transport element608 and a heating element 610. The liquid transport element 608 maycomprise a porous monolith. For example, the liquid transport element608 may comprise a ceramic.

The heating element 610 may comprise a wire, which may be coiled aboutthe liquid transport element 608. In some embodiments the wire maycomprise titanium, Kanthal (FeCrAl), Nichrome, Molybdenum disilicide(MoSi₂), molybdenum silicide (MoSi), Molybdenum disilicide doped withAluminum (Mo(Si,Al)₂), graphite and graphite-based materials; ceramic(e.g., a positive or negative temperature coefficient ceramic),Tungsten, and Tungsten-based alloys, or any other suitable materials,such as those noted elsewhere herein. Usage of Tungsten andTungsten-based alloys may be desirable in that these materials maydefine a coefficient of expansion suitable for usage with many ceramics,which may be employed in the liquid transport element 608.

The wire of the heating element 610 may be at least partially imbeddedin the liquid transport element 608. In this regard, the wire of theheating element 610 may be imbedded in the liquid transport element 608before the liquid transport element is fired in a high temperature ovenknown as a kiln. For example, the wire may be wrapped about a longsection of the base material from which the ceramic is formed prior tofiring the material. Examples of such base material employed to form theceramic in the liquid transport element 608 may include clay, oxides,nonoxides, and composites. Thereby, the wire may at least partiallyimbed in the base material during wrapping thereabout. The base materialand the wire may then be fired in the kiln. Afterwards, a gang saw orother cutting device may divide the product into individual atomizers606 having a desired length.

The atomizer 606 may further comprise a capillary rod 612. In thisregard, the liquid transport element 608 may define a tube. In otherwords, the liquid transport element 608 may include an apertureextending longitudinally therethrough. Thereby, the capillary rod 612may extend longitudinally through the liquid transport element 608. Assuch, the capillary rod 612 may be configured to direct the aerosolprecursor composition through the liquid transport element 608. In thisregard, the spacing between the capillary rod 612 and the inner surfaceof the liquid transport element 608 may define a capillary channel thatdirects the aerosol precursor composition therethrough. The aerosolprecursor composition may then be drawn generally radially outwardlythrough the liquid transport element 608 during activation of theheating element 610.

The atomizer body 600 (see, FIG. 4) may additionally include a firstatomizer seal 614, which is illustrated in FIG. 9. The first atomizerseal 614 may engage a first end of the liquid transport element 608 anda first end of the capillary rod 612, which may define a head portion616. Thereby, the liquid transport element 608 may be sealed to the headportion 616 of the capillary rod 612 to prevent leakage of the aerosolprecursor composition therebetween.

FIG. 10 illustrates an exploded view of the base 604 and a plurality ofterminals configured to engage the base. The terminals include a firstheating terminal 618, a second heating terminal 620, and an electroniccomponent terminal 622. The electronic component terminal 622 may beengaged with an electronic component 624 that verifies that the atomizerbody 600 (see, e.g., FIG. 8) is genuine and/or provides other functionsas described elsewhere herein.

The assembled configuration of the terminals 618, 620, 622 (see, FIG.10) and the base 604 is illustrated in FIG. 11. As illustrated, thefirst heating terminal 620 may include a first clip 626. Further, thesecond heating terminal 620 may include a second clip 628.

As illustrated in FIG. 12, the first clip 626 and the second clip 628may be aligned such that the liquid transport element 608 may bereceived therein and held in place. In this regard, the liquid transportelement 608 may be inserted from a side through openings at each clip626, 628 into engagement therewith. The first clip 626 and the secondclip 628 may contact opposing ends of the heating element 610, such thatcurrent may be directed therethrough via the first heating terminal 618and the second heating terminal 620. In some embodiments the clips 626,628 may be welded (e.g., laser welded) to the heating element 610 toprovide a secure connection therewith. For example, laser beams may bedirected at each of the clips 626, 628, which may cause welds to formthe clips and the heating element 610.

The atomizer body 600 (see, e.g., FIG. 4) may additionally include asecond atomizer seal 630 and an atomizer body seal 632. As illustratedin FIG. 8, the atomizer body seal 632 may extend over the liquidtransport element 608 and the heating terminals 618, 620 and intoengagement with the base 604. As further illustrated in FIG. 8, thesecond atomizer seal 630 may be configured to engage the second end ofthe liquid transport element 608. Thereby the atomizer body seal 632 mayextend over the liquid transport element 608 and the first and secondheating terminals 618, 620 such that the liquid transport element cannotdecouple from the first clip 626 (see, e.g., FIG. 12). Similar, thesecond atomizer seal 630 may extend over the liquid transport element608 and the second heating terminal 620 such that the liquid transportelement cannot decouple from the second clip 628 (see, e.g., FIG. 12).Accordingly, the liquid transport element 608 may remain in engagementwith the heating terminals 618, 620.

Further, the second atomizer seal 630 and the atomizer body seal 632 mayform seals. In this regard, the atomizer body seal 632 may seal againstthe base 604 and the outer body 602 when the outer body is engagedtherewith. The second atomizer seal 630 and the atomizer body seal 632may each engage inner surfaces of the outer body 602 to prevent leakage.In particular, the second atomizer seal 630 may engage an inner surfaceof the outer body 602 such that the aerosol precursor composition doesnot leak between the liquid transport element 608 and the outer body,but is instead directed through the longitudinal aperture definedthrough the liquid transport element.

Further, the atomizer body seal 632 may engage the inner surface of theouter body 602 and the base 604. Thereby, air may only enter theatomizer body 602 during a user draw through the base 604 through theatomizer body seal 632. In this regard, the atomizer body seal 632 mayinclude one or more air flow apertures 634 configured to receive the airfrom the base 604 and direct the air to the outside of the atomizer 606.As discussed below, the aerosol produced at the atomizer 606 may then bedirected out of the atomizer body 600 through the cartridge 500 (see,e.g., FIG. 4) to the user.

Operation of the aerosol delivery device 400 is described hereinafter ingreater detail. As illustrated in FIG. 13, the atomizer body 600 may beengaged with the control body 200. Further, the cartridge 500 may beengaged with the atomizer body 600 such that the atomizer body ispositioned between the control body and the cartridge 500. However, asmay be understood, the atomizer body 600, the control body 200, and thecartridge 500 may be arranged differently in other embodiments.

The connection between the control body 200 and the atomizer body 600via the first and second heating terminals 618, 620 and the electroniccomponent terminal 622 (see, e.g., FIG. 10) allows the control body 200to direct electrical current to the atomizer 606 when a puff on theaerosol delivery device 400 is detected. In this regard, a longitudinalend of the cartridge 500 opposite from the atomizer body 600 may definea mouthpiece 528. When the user draws on the mouthpiece 528, air 223 maybe directed through an air intake 224, which may be defined between thecoupler 202 and the outer body 204 of the control body 200. The air 223drawn through the air intake 224 may be drawn through the coupler 202 ofthe control body 200 and then through the base 604 and the atomizer bodyseal 632 into an atomization cavity 638 of the atomizer body 600.Further, the air 223 may cool the electronic component 624 (see, e.g.,FIG. 10) as it passes through the base 604 to reduce risk with respectto temperature-related degradation thereof.

The air 223 may be drawn through the air intake 224, as opposed tothrough the connection between the cartridge 500 and the atomizer body600 due to inclusion of an O-ring 640 at an outer surface thereof, whichmay engage and seal against an inner surface of the reservoir 502 of thecartridge 500. Further, the reservoir 502 may define a detent 530 at aninner surface thereof that may engage a recess 642. Thereby, theatomizer body 600 may remain in secure engagement with the cartridge500. To the extent any air enters the aerosol delivery device 400between the control body 200 and the atomizer body 600, rather thanthrough the air intake 224, this air may be combined with the airreceived through the air intake 224 at the atomization cavity 638.

The detent 530 and the recess 642 may additionally or alternativelyprovide other functions. In this regard, in some embodiments engagementof the detent 530 with the recess 642 may be required in order to allowfor operation of the device. For example, engagement of the detent 530with the recess 642 may complete a circuit with the electronic component624 (see, e.g., FIG. 10), required for operation of the aerosol deliverydevice.

As the air is drawn through the air intake 224, the flow sensor 210(see, FIG. 2) may detect the draw. Thereby, the control body 200 maydirect current through the heating terminals 618, 620 to the atomizer606. As the atomizer 606 heats, the aerosol precursor composition 506may be vaporized at the atomizer. In this regard, the aerosol precursorcomposition 506 may be retained in a precursor cavity 532 in thereservoir 502. The aerosol precursor composition 506 may be directedthrough the valve assembly 504 to the atomizer 606.

In this regard, the valve assembly 504 may be configured to dispense theaerosol precursor composition 506 to the atomizer body 600 when engagedtherewith. At other times the valve assembly 504 may remain in a closedconfiguration so as to retain the aerosol precursor composition 506 inthe reservoir 502. More particularly, the atomizer body 600 may includea nozzle 644. The nozzle 644 may be configured to engage the valveassembly 504. In this regard, the nozzle 644 may be configured to extendthrough the reservoir seal 524 and engage the dispensing seal 526.Accordingly, the aerosol precursor composition 506 retained in theprecursor cavity 532 may be directed through the valve assembly 504 tothe nozzle 644.

As illustrated in FIGS. 14 and 15, the aerosol precursor composition 506may flow through a gap defined between the radial outer edges of thefirst plate 516 and the second plate 518 of the valve assembly 504 andan inner surface of the reservoir 502 and into a space defined betweenthe first plate and the second plate. More particularly, FIG. 15illustrates an enlarged view of area Z from FIG. 14. As illustrated,capillary action may draw the aerosol precursor composition 506 betweenthe first plate 516 and the second plate 518.

In some embodiments internal surfaces of the first plate 516 and thesecond plate 518 may define an angle with respect to each other. Inparticular, the first plate 516 and the second plate 518 may be shapedand configured such that the internal surfaces are furthest from oneanother proximate the outer edges thereof, and closest to one anotherproximate the dispensing capillary tube 522. Thereby a distance betweenthe first plate 516 and the second plate may decrease from the outeredges of the plates towards the centers thereof. For example, the innersurfaces of the first plate 516 and the second plate 518 may define anangle with respect to one another, which may be between about 1 degreesand about 5 degrees in some embodiments. By configuring the first plate516 and the second plate 518 in this manner, a “draft” may be created,which draws the aerosol precursor composition toward the dispensingcapillary tube 522. Accordingly, the aerosol precursor composition maybe drawn into the dispensing capillary tube 522 (see, e.g., FIG. 13)defined through the first plate, such that flow of the aerosol precursorcomposition thereto may occur in any orientation in which the aerosolprecursor composition contacts the first plate 516 and the second plate518. Further, an entrained volume of the aerosol precursor composition506 in the valve assembly 504 and downstream components may allow forcontinued operation in any orientation (e.g., about fifteen to twentypuffs) before the orientation of the aerosol delivery device 400 (see,e.g., FIG. 13) would need to be changed to one in which the aerosolprecursor composition contacts the first plate 516 and the second plate518.

Further, the dispensing seal may seal against the nozzle 644. This mayisolate a nozzle orifice at an end of the nozzle 644 in order to drawaerosol precursor composition from the fluid volume between the firstplate 516 and the second plate 518. This configuration operates as athermal pump, providing additional efficiency in the transport of theaerosol precursor composition and more efficient extraction ofsubstantially all of the aerosol precursor composition from theprecursor cavity 532. In other words, this design is configured to allowsubstantially complete consumption of the aerosol precursor compositioncontain such that the cartridge 500 can be run “dry,” such that theconsumer does not perceive any residual aerosol precursor compositionleft in the precursor cavity 532.

Thereby, as illustrated in FIG. 13, the aerosol precursor composition506 may be directed through the nozzle 644 into the liquid transportelement 608. The aerosol precursor composition 506 may then be vaporizedby the heating element 610 directly or via heating of the liquidtransport element 608. Accordingly, the resultant vapor or aerosol 646may be produced at the atomization cavity 638 and then be directed tothe user. In this regard, the outer body 602 of the atomizer unit 600may include one or more air flow apertures 648 extending therethroughand in fluid communication with the atomization cavity 638. Further, oneor more air flow apertures 534 may be defined through the reservoir seal524 of the valve assembly 504 and align with the air flow apertures 648extending through the outer body 602 of the atomizer unit 600.

Additionally, the reservoir 502 may include one or more air flowapertures 536 extending from the valve assembly 504 to the mouthpiece528. The air flow apertures 536 extending through the reservoir 502 maybe separated from the precursor cavity 532 in which the aerosolprecursor composition 506 is received. In this regard, the air flowapertures 536 may be defined through the material forming the reservoir502 circumferentially about the precursor cavity 532. Accordingly, theaerosol 646 may be directed from the atomization cavity 638 through themouthpiece 528 to the user.

As described above with reference to FIG. 13, the cartridge 500 mayinclude the aerosol precursor composition 506 and the atomizer body 600may include the atomizer 606. By allowing for replacement of thecartridge 500 without requiring replacement of the atomizer 606 at thesame time, the cost associated with usage of the aerosol delivery device400 may be reduced. In this regard, in some embodiments the atomizer 606may have a useable life configured to atomize a quantity of aerosolprecursor composition 506 contained in about two hundred to about threehundred cartridges 500 before requiring replacement.

In contrast, the cartridge 500 may be configured to be discarded afterthe aerosol precursor composition 506 is depleted therefrom. In thisregard, the cartridge 500 may be configured to prevent refillingthereof. FIG. 16 illustrates a view of the cartridge 500 at the valveassembly 504. As illustrated, the reservoir seal 524 may define anorifice 538 configured to guide and receive the nozzle 644 of theatomizer body 600 (see, e.g., FIG. 13), as described above. As may beunderstood, a user may attempt to employ the orifice 538 to refill thereservoir 502 with aerosol precursor composition. However, the valveassembly 504 may be configured to resist refilling.

In this regard, the frame 510 may include one or more protrusions 540that extend outwardly from the reservoir seal 524. In some embodimentsthe protrusions 540 may be defined by the connector portions 514 (see,FIG. 7) of the frame 510. As a result of the protrusions 540 protrudingoutwardly from the reservoir seal 524, a bottle nozzle or glass drippermay not be able to form a face seal with respect to the reservoir seal,which may be required to allow flow of fluid through the reservoir seal.In this regard, the reservoir seal 524 and the dispensing seal 526 (see,FIG. 7) may define valves that are closed in an unbiased configurationand which open during engagement with the nozzle 644 when the cartridge500 engages the atomizer body 600 (see, e.g., FIG. 13). As a result ofresisting the formation of seal with respect to most bottle nozzles andglass drippers, the reservoir seal 524 may thereby resist refilling ofthe reservoir 502.

Further, by employing two or more of the protrusions 540 around theorifice 538, a width of any nozzle that may engage the orifice 538 maybe restricted to further limit the type of nozzle that may extendthrough the orifice and/or form a face seal therewith. In someembodiments the orifice may define a diameter from about one millimeterto about three millimeters, which may be too small for standard e-liquidbottle nozzles or glass dropper tips to be inserted therein. Further,usage of both the reservoir seal 524 and the dispensing seal 526, eachformed from a resilient material and separated from one another, maymake it difficult to employ a hypodermic needle to refill the reservoir502.

Attempts to refill the cartridge 500 by forming a seal with an innersurface of the base 512 of the frame 510 to refill the reservoir 502 mayalso fail. In this regard, the air flow apertures 534 defined in thereservoir seal 524 would allow aerosol precursor composition to flow outof the cartridge 500 through the air flow apertures 536 (see, FIG. 13)defined in the reservoir 502, thereby resisting refilling of thereservoir 502.

Additionally, as noted above, the valve assembly 504 may be recessed inand affixed to the reservoir 502 (e.g., via ultrasonic welding). Assuch, the valve assembly 504 may not be removed from the reservoir 502without damaging one or both of these components, thereby furtherresisting refilling of the cartridge 500). Additionally, in view of theatomizer 606 being included in a separate atomizer body 600 (see, e.g.,FIG. 13) instead of in the cartridge 500, the cartridge may be pricedrelatively more inexpensively, which may mitigate cost savings as adriving factor for a user attempting to refill the cartridge.

In an additional embodiment an aerosol delivery device operation methodis provided. As illustrated in FIG. 17, the method may include directingan aerosol precursor composition from a reservoir of a cartridge out ofthe cartridge through a valve assembly at operation 702. Directing theaerosol precursor composition from the reservoir of the cartridge out ofthe cartridge through the valve assembly at operation 702 may includedirecting the aerosol precursor composition through a dispensingcapillary tube, a dispensing seal at the dispensing capillary tube and areservoir seal at the reservoir. Further, the method may includereceiving the aerosol precursor composition in an atomizer body atoperation 704. The method may additionally include directing the aerosolprecursor composition to an atomizer in the atomizer body at operation706. The method may further include directing an electrical current froma control body to the atomizer to produce an aerosol at operation 708.

In some embodiments directing the aerosol precursor composition out ofthe cartridge through the valve assembly at operation 702 may furtherinclude directing the aerosol precursor composition between a firstplate and a second plate positioned adjacent to one another with a spacedefined therebetween and out of the space through the dispensingcapillary tube extending through the first plate. Directing the aerosolprecursor composition out of the cartridge through the valve assembly atoperation 702 may further include engaging a nozzle of the atomizer bodywith the valve assembly. Engaging the nozzle with the valve assembly mayinclude directing the nozzle through the reservoir seal of the valveassembly. Engaging the nozzle with the valve assembly may furtherinclude engaging the nozzle with the dispensing seal of the valveassembly at the dispensing capillary tube.

In some embodiments receiving the aerosol precursor composition in theatomizer body at operation 704 comprises directing the aerosol precursorcomposition between the nozzle and a capillary rod. Directing theaerosol precursor composition to the atomizer in the atomizer body atoperation 706 may include directing the aerosol precursor compositionbetween the capillary rod and a liquid transport element of theatomizer. The method may further include directing the aerosol throughone or more air flow apertures extending through the cartridge.Directing the aerosol through one or more air flow apertures extendingthrough the cartridge may include directing the aerosol through thevalve assembly.

As may be understood, the apparatuses and method of the presentdisclosure may vary. In this regard, FIG. 18 illustrates a cartridge 800and an atomizer 900 according to an additional example embodiment of thepresent disclosure. In particular, FIG. 18 illustrates the cartridge 800and the atomizer 900 in an assembled configuration, and engaged with oneanother. The atomizer 900 may be configured to engage a control bodysuch as the control body 200 (see, e.g., FIG. 2) described above. Itshould be noted that with regard to this embodiment, the atomizer 900may also comprise the atomizer body and thus the terms atomizer andatomizer body may be used interchangeably. Where not otherwise describedand/or illustrated, the components of an aerosol delivery deviceaccording to this embodiment may be substantially similar to, or thesame as, corresponding components described above.

FIGS. 19 and 20 illustrate the atomizer 900 by itself. FIG. 19illustrates the atomizer 900 in an assembled configuration (minus alabel 902), whereas FIG. 20 illustrates the atomizer body in an explodedconfiguration. As illustrated, the atomizer 900 may include the label902, a base 904, an atomizer air valve 906, a terminal base 908, a firstheating terminal 910, a second heating terminal 912, a liquid transportelement 914, a flow director 916, an outer o-ring 918, and an outer body920. As illustrated in FIG. 19, the outer body 920 may include a nozzle922 and a plurality of vapor apertures 924.

In various embodiments, a control body may be configured to releasablyengage the atomizer 900. Further, the atomizer 900 may be configured toreleasably engage the cartridge 800. As described hereinafter, theatomizer 900 may be configured to receive an electrical current from thecontrol body and the aerosol precursor composition from the cartridge800 to produce an aerosol.

Referring to FIG. 20, the atomizer 900 may also include a terminal base908. In various embodiments, the terminal base may be constructed of aplastic material, including, but not limited to, a silicone, athermoplastic polyurethane, or another resilient material. An examplecommercially-available material that may be used for the terminal baseis TRITAN copolyester, sold by Eastman Chemical Company of Kingsport,Tenn. In the illustrated embodiment, the first heating terminal 910 andthe second heating terminal 912 pass through the terminal base 908. Invarious embodiments, the first heating terminal 910 and the secondheating terminal 912 may be inserted molded within the terminal base908. In such a manner, the terminal base 908 may comprise an overmoldwith the first heating terminal 910 and the second heating terminal 912fixedly attached therein.

FIGS. 21 and 22 illustrate separate views of the cartridge 800. Asillustrated, the cartridge 800 may include an internal reservoir 802 anda central passageway 804. The cartridge may also include a dispensingvalve 806 and a substantially circular vapor flow groove 808 defined ina bottom surface of the cartridge 800 that leads to a pair of verticalcartridge vapor channels 810. As with the embodiments described above,the reservoir 802 may be configured to contain an aerosol precursorcomposition. In some embodiments the cartridge 800 may comprise atranslucent or transparent material, such that a user may view thequantity of the aerosol precursor composition remaining therein. Theaerosol precursor composition may be dispensed or otherwise directedinto the reservoir 802. The valve 806 may seal the aerosol precursorcomposition in the reservoir 802. However, as described hereinafter, thevalve 806 may allow the aerosol precursor composition to flow to theatomizer 900 when engaged therewith.

FIG. 23 illustrates an example embodiment of the liquid transportelement 914. Also shown are a heating element 926 for use with theatomizer 900, the first heating terminal 910, and the second heatingterminal 912. Note that to simply the figure, the terminal base 908 isnot shown. In various embodiments, the liquid transport element 914 maycomprise a porous monolith. For example, the liquid transport element608 may comprise a ceramic. As illustrated, the heating element 926 maycomprise a wire, which may be coiled about an inside surface of theliquid transport element 914. In some embodiments, the wire may comprisetitanium, Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂),molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum(Mo(Si,Al)₂), graphite and graphite-based materials; ceramic (e.g., apositive or negative temperature coefficient ceramic), Tungsten, andTungsten-based alloys, or any other suitable materials, such as thosenoted elsewhere herein. Usage of Tungsten and Tungsten-based alloys maybe desirable in that these materials may define a coefficient ofexpansion suitable for usage with many ceramics, which may be employedin the liquid transport element 914.

The wire of the heating element 926 may be at least partially imbeddedin the liquid transport element 914. In this regard, the wire of theheating element 926 may be imbedded in the liquid transport element 914before the liquid transport element is fired in a high temperature ovenknown as a kiln. In various embodiments, the first heating terminal 910contacts one end of the heating element 926 and the second heatingterminal 912 contacts another end of the heating element 926, such thatan electric current can be passed through the heating element 926.

As noted above, in some embodiments, thermally coupling of the heatingelement 926 to the liquid transport element 914 may occur via embeddingor partially embedding the heating element 926 in the liquid transportelement 914. In other embodiments, thermally coupling the heatingelement to the liquid transport element may occur via “direct writing,”which may comprise computer aided surface deposition of specializedalloyed flowable metals to a substrate. In other embodiments, theheating element may be coupled to the liquid transport element viaplating, electroplating, direct deposition (e.g., sputtering), and/orother suitable methods.

As also shown in FIG. 23, in various embodiments, the liquid transportelement 914 may include an external electrical connection 927, which maybe the external component of the electrical pathway between the heatingterminals 910 and 912 and the heating element 926. In the depictedembodiment, the external electrical connection 927 comprises a helicalcoil in and/or on the outer surface of the liquid transport element 914.In various embodiments, the external electrical connection may havefunctional characteristics with regard to the thermal performance of theheating element and liquid transport element. As with the heatingelement described above, the external electrical connection may be adirectly written or partially embedded element.

In some embodiments, it may be desirable to decrease thermal transferfrom the heating element to the device (most directly via the atomizerhousing) and therefor the user, and/or to decrease thermal degradationof the device (as discussed in this draft in regards to air cooling ofelectrical components), and/or to increase the efficiency of the heatgenerated by the heating element and applied to the aerosol precursorcomposition to effect mass transfer of precursor to aerosol or vapor(with associated efficiency benefits such as decreased power consumptionand increased overall system efficiency). Thus, in some embodiments, theexternal electrical connection may be comprised of a material dissimilarin thermal conductivity to that of the liquid transport element, thuscreating a thermal gradient across the liquid transport element withgreater thermal conductivity across the internal surface of the liquidtransport element than the external surface.

In some embodiments, the mass of the material could also be utilized toeffect an increased differential of the time delta for heat transferthrough the liquid transport element. In addition, many processesincluding direct writing and those mentioned above can by utilized toselectively alter the characteristics of the liquid transport element.In addition, the application of concurrent or post-firing processes that“dope” the surface of the material and can penetrate to selected depthsof the substrate depending on substrate porosity, material composition,process and application are possible approaches. In various embodiments,conductive non-porous ceramic based materials could also be utilized forthe liquid transport element. In this regard, a thermal gradient mayexist across the cross-section of the liquid transport element, with asubstantially hotter area across the internal surface of the liquidtransport element to effect phase transition and mobilization of theprecursor composition, with the external surface of the liquid transportelement remaining relatively cooler serving to insulate and isolate theheat to the atomization chamber.

Alternatively, it may be desirable to simply insulate the direct regionof the external electrical connection that makes connection with thefirst and second heating terminals. In such embodiments, the externalelectrical connection could also serve as a restive heater itself. Inthis capacity, the external electrical connection and the heatingelement may have dissimilar resistance characteristics such that theexternal electrical connection may help to overcome an initial thermalramp required in the initial heating phase of a user activation process.In such embodiments, the external electrical connection may not reachtemperatures required for mobilization of the precursor. Rather, theexternal electrical connection may heat to a lower temperature than thatof the heating element. This could increase vapor product over time bydecreasing the time delta from activation to aerosol generation. In thiscapacity the external electrical connection may also warm the proximateprecursor located in and adjacent to the liquid transport element bydecreasing the viscosity of the precursor, facilitating increasedtransport to the liquid transport element.

FIG. 24 illustrates an isometric view of the flow director 916 for usewith the atomizer 900. FIG. 25 illustrates a cross-sectional view of theflow director 916. In various embodiments, the flow director 916 maygenerally have a “T” shape that includes an upper flange 925 and a lowercylinder 927. The flow director further includes a central inlet airchannel 928, a series of inlet air holes 930, a transition barrier 931,and a series of inlet vapor holes 932. The inlet vapor holes 932 lead toa series of radial vapor channels 934 located in the upper flange 925,which each leads to a vertical vapor hole 936. The flow director alsoincludes a series of inlet liquid flow channels 938 located on the upperflange 925, which, when assembled with the liquid transport element 914,abut a top surface thereof. It should be noted that although the distalends of the radial vapor channels shown in FIG. 25 appear to extendthrough holes in an outer surface of the upper flange 925, in suchembodiments, these holes are sealed or otherwise occluded so as tocreate a direct flow path though the radial vapor channels 934 and intothe vertical vapor holes 936 (see FIG. 26). In other embodiments, theradial vapor channels may terminate at the vertical vapor holes, suchthat there are no openings along the outer surface of the upper flange.

Operation of an example embodiment of an aerosol delivery device isdescribed hereinafter in greater detail. As noted above, the atomizer900 may be engaged with the control body 200, and, as illustrated inFIGS. 26 and 27 the cartridge 800 may be engaged with the atomizer 900such that the atomizer 900 is positioned between the control body 200and the cartridge 800. However, as may be understood, the atomizer 900,the control body 200, and the cartridge 800 may be arranged differentlyin other embodiments.

In this regard, when the cartridge 800 is coupled to the atomizer 900and control body 200, the nozzle 922 of the atomizer 900 may beconfigured to engage with the dispensing valve 806 of the cartridge 800.In such a manner, the aerosol precursor composition 506 may flow throughthe cartridge 800 and into the nozzle 922 of the outer body 920 of theatomizer 900. Due to the relative position of the flow director 916 whencoupled with the outer body 920 and via capillary action, the aerosolprecursor composition 506 may be drawn through a series of radial flowopenings 940 onto the top of the upper flange 925 of the flow director916 (see FIG. 26). From there, the aerosol precursor composition may bedrawn through the inlet liquid flow channels 938 that extend verticallythrough the upper flange 925 of the flow director 916, and onto the topsurface of the liquid transport element 914 (see FIG. 27). In such amanner, an atomizer chamber 942 is created on the inside of the liquidtransport element 914, bounded by the flow director 916 and the terminalbase 908. In some embodiments, the aerosol precursor composition may bedrawn through the inlet liquid flow channels 938 onto an outside surfaceof the liquid transport element 914 in addition to or instead of the topsurface of the liquid transport element 914.

A connection between the control body 200 and the atomizer 900 via thefirst and second heating terminals 910, 912 allows the control body 200to direct electrical current to the atomizer 900 when a puff on theaerosol delivery device 400 is detected. In this regard, a longitudinalend of the cartridge 800 opposite from the atomizer 900 may define amouthpiece. When the user draws on the mouthpiece, air 223 may bedirected through the atomizer base 904 and the atomizer air valve 906,and into the central inlet air channel 928 of the flow director 916. Inparticular, as the air is drawn into the aerosol delivery device, theflow sensor 210 (see, FIG. 2) may detect the draw. Thereby, the controlbody 200 may direct current through the heating terminals 910, 912 tothe atomizer 900. In some embodiments, the upstream air 223 may cool anelectronic component before it flows into the central air channel 928 toreduce risk with respect to temperature-related degradation thereof. Asthe atomizer 900 heats, the aerosol precursor composition 506 may bevaporized by the heating element 926 via heating of the liquid transportelement 914, which absorbs the aerosol precursor composition 506therein. Accordingly, the resultant vapor or aerosol 646 may be producedon the inside surface of the liquid transport element 914 and/or withinthe atomizer chamber 942.

When the air 223 flows through the central inlet air channel 928, it isdirected through the series of first inlet air holes 930 of the lowercylinder 927 by the transition barrier 931 (see FIG. 26) and into theatomizer chamber 942 (i.e., past the inside surface of the liquidtransport element 914) where it becomes the vapor or aerosol 646. Due tothe geometry and relative arrangement of the flow director 916 and theouter body 920, including a diverting feature 933 of the outer body 920,which is configured to fit into and occlude the central opening in thetop of the flow director 916, the resultant vapor or aerosol 646 travelsthrough the series of radial vapor channels 934 in the upper flange 925of the flow director 916, up through the series of vertical vapor holes932, and through at least some of the plurality of vapor apertures 924in the outer body 920.

It should be noted that the “tortuous path” of the aerosol through theupper flange 925 of the flow director 916 via the inlet vapor holes 932,radial vapor channels 934, and vertical vapor holes 936, may have thefunctional roll of creating a series of impaction surfaces configured tocapture aerosol droplets outside of (i.e., larger) an optimal range. Insuch a manner, droplets having a greater mass may not remain entrainedin the airflow as the path makes 90 degree turns through the inlet vaporholes 932, the radial vapor channels 934, and the vertical vapor holes936 and may thus impact within the upper flange 925, where they maydrain back into the atomizer chamber 942.

FIG. 28 shows the flow of the vapor or aerosol 646 through the cartridge800, leading to the central passageway 804. When the cartridge 800 iscoupled to the atomizer 900, the circular vapor flow groove 808 of thecartridge 800 is configured to substantially align with the plurality ofvapor apertures 924 of the outer body 920 of the atomizer 900. As such,vapor or aerosol 646 flowing through the plurality of vapor apertures924 may be directed by the vapor flow groove 808 into the verticalcartridge vapor channels 810. As shown in the figure, the vertical vaporchannels 810 lead to respective horizontal vapor channels 812, whichthen lead to the central passageway 804 of the cartridge 800.

As described above with reference to additional implementations, thecartridge 800 may include the aerosol precursor composition 506. Byallowing for replacement of the cartridge 800 without requiringreplacement of the atomizer 900 at the same time, the cost associatedwith usage of the aerosol delivery device may be reduced. In thisregard, in some embodiments the atomizer 900 may have a useable lifeconfigured to atomize a quantity of aerosol precursor composition 506contained in about two hundred to about three hundred cartridges 800before requiring replacement.

In contrast, the cartridge 900 may be configured to be discarded afterthe aerosol precursor composition 506 is depleted therefrom. In thisregard, the cartridge 800 may be configured to prevent refilling thereofas similarly described with respect to the embodiments illustratedabove. For example, FIG. 22 illustrates a bottom view of the cartridge800. As illustrated, the dispensing valve 806 may define an orifice 814configured to guide and receive the nozzle 922 of the atomizer 900, asdescribed above. As may be understood, a user may attempt to refill thereservoir 802 with aerosol precursor composition; however, the cartridge800 may be configured to resist refilling.

In this regard, the cartridge 800 may include one or more protrusions816 that extend inwardly from an area proximate the vapor flow groove808, toward the dispensing seal 806. As a result of the protrusions 816protruding inwardly toward the dispensing seal 806, a bottle nozzle orglass dripper may not be able to form a face seal with respect to thedispensing seal, which may be required to allow flow of fluid throughthe dispensing seal. In this regard, the dispensing seal 806 may definea valve that is closed in an unbiased configuration and which openduring engagement with the nozzle 922 when the cartridge 800 engages theatomizer 900. As a result of resisting the formation of seal withrespect to most bottle nozzles and glass drippers, the dispensing seal806 may thereby resist refilling of the reservoir 802. Further, byemploying two or more of the protrusions 816 around the orifice 814, awidth of any nozzle that may engage the orifice 806 may be restricted tofurther limit the type of nozzle that may extend through the orificeand/or form a face seal therewith. In some embodiments the orifice maydefine a diameter from about one millimeter to about three millimeters,which may be too small for standard e-liquid bottle nozzles or glassdropper tips to be inserted therein.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1. An aerosol delivery device, comprising: a control body; an atomizerbody comprising an atomizer; and a cartridge comprising a reservoirconfigured to contain an aerosol precursor composition, and a valveassembly configured to dispense the aerosol precursor composition to theatomizer body when the cartridge is engaged with the atomizer body,wherein the control body is configured to releasably engage the atomizerbody, and the atomizer body is configured to releasably engage thecartridge, wherein the atomizer is configured to receive an electricalcurrent from the control body and the aerosol precursor composition fromthe cartridge to produce an aerosol, and wherein the control body, theatomizer body, and the cartridge comprise separate components.
 2. Theaerosol delivery device of claim 1, wherein the cartridge comprises oneor more air flow apertures extending from the atomizer body to amouthpiece, the air flow apertures being configured to direct theaerosol therethrough.
 3. The aerosol delivery device of claim 2, whereinat least one of the air flow apertures extends through the valveassembly.
 4. The aerosol delivery device of claim 1, wherein theatomizer body further comprises a nozzle configured to engage with thevalve assembly.
 5. The aerosol delivery device of claim 1, wherein theatomizer comprises a liquid transport element comprising a porousmonolith.
 6. The aerosol delivery device of claim 5, wherein theatomizer further comprises a heating element comprising a wire at leastpartially imbedded in the liquid transport element.
 7. The aerosoldelivery device of claim 6, wherein the liquid transport element definesa tube and the atomizer further comprises a capillary rod extendingthrough the liquid transport element and configured to direct theaerosol precursor composition therethrough.
 8. The aerosol deliverysystem of claim 1, wherein the control body further comprises amicrophone, the microphone being configured to detect a user draw on thecartridge.
 9. The aerosol delivery system of claim 1, wherein theatomizer comprises an outer body, a terminal base, a flow director, anda liquid transport element comprising a porous monolith, and wherein anatomizer chamber is created by the flow director, the terminal base, andan inside surface of the liquid transport element.
 10. The aerosoldelivery system of claim 9, wherein the flow director includes a centralinlet air channel, a transition barrier, and one or more radial inletair holes configured such that air that enters through the inlet airchannel is directed through the one or more radial inlet air holes bythe transition barrier.
 11. The aerosol delivery system of claim 10,wherein the flow director further includes one or more inlet liquid flowchambers configured to deliver the aerosol precursor composition to theliquid transport element.
 12. The aerosol delivery system of claim 11,wherein the outer body includes one or more vapor apertures, and theflow director further includes one or more radial inlet vapor holes, oneor more radial vapor channels, and one or more vertical vapor holes,configured such that the aerosol is directed through the one or moreradial inlet vapor holes, the one or more radial vapor channels, the oneor more vertical vapor holes of the flow director, and the one or morevapor apertures of the outer body and into one or more vapor channels ofthe cartridge.
 13. An aerosol delivery device operation method,comprising: providing a control body, an atomizer body, and a cartridge,wherein the control body, the atomizer body, and the cartridge compriseseparate components; directing an aerosol precursor composition from areservoir of the cartridge out of the cartridge through a valveassembly; receiving the aerosol precursor composition in the atomizerbody; directing the aerosol precursor composition to an atomizer in theatomizer body; and directing an electrical current from the control bodyto the atomizer to produce an aerosol.
 14. The aerosol delivery deviceoperation method of claim 13, wherein directing the aerosol precursorcomposition out of the cartridge through the valve assembly furthercomprises engaging a nozzle of the atomizer body with the valveassembly.
 15. The aerosol delivery device operation method of claim 13,further comprising directing the aerosol through one or more air flowapertures extending through the cartridge.
 16. The aerosol deliverydevice operation method of claim 15, wherein directing the aerosolthrough one or more air flow apertures extending through the cartridgeincludes directing the aerosol through the valve assembly.
 17. Theaerosol delivery device operation method of claim 13, wherein directingthe aerosol precursor composition to an atomizer in the atomizer bodycomprises directing the aerosol precursor composition through one ormore radial flow openings in an outer body of the atomizer and throughone or more inlet liquid flow channel in a flow director of theatomizer.
 18. The aerosol delivery operation method of claim 17, furthercomprising directing the aerosol through one or more radial inlet vaporholes, one or more radial vapor channels, and one or more vertical vaporholes of the flow director, one or more vapor apertures of an outer bodyof the atomizer, and into one or more vapor channels of the cartridge.